From the Sector

To expand its support for high-end and luxurious automotive interiors, B.I.G. Yarns has completed its first industrial production runs of virgin polyester BCF yarns for automotive carpet to complement its line of polyamide PA6 superior yarns.

There is a growing market in PET for automotive interior applications, with polyester allowing automotive OEMs and Tier 1 to develop products that, from the outset, consider eco-design by building MONO-polymer carpets and flooring that are 100% recyclable at End of Life (EOL ). These materials are helping to ensure improved and more sustainable EOL recycling of electric vehicles that are driving the future of the car industry.

The new PET BCF Yarns offer high-performance for automotive carpets, including abrasion and stain resistance, and durability, passing all stringent automotive tests including the Taber test for abrasion performance, compressibility and recovery ability test, light fastness in automotive (DIN EN ISO 105-B06) and VOC (fogging) according the VDA 278 test on VOC and FOG emission. The yarns can be color solution dyed, have a dTex between 1300 – 1500, 81 filaments and are ideally for mats with a composition of 400 to 800 gram per m², while the yarns for molded carpets have a dTex of 1200, 144 filaments for 380 gram per m².

With the addition of PET BCF yarns, B.I.G. Yarns is now a one-stop-shop for 3 types of Solution Dyed BCF carpet yarns for the automotive industry: nylon (PA6), polypropylene (PP) and polyester (PET), and the Eqo-range of PA6 yarns – the sustainability focused EqoBalance, EqoCycle and EqoYarn.

The automotive carpet market is expected to grow strongly in the coming decade with the increased demand for vehicle customization and personalization driven by owners looking to upgrade and enhance interiors, including the flooring area.
A growing awareness around car hygiene is also boosting the market as consumers become more conscious of maintaining cleanliness in their vehicles, including the floors. Automotive carpets provide an effective solution by trapping dirt and preventing it from spreading to other areas.

With its new sustainability label Autoneum Blue, Autoneum combines the use of recycled materials with protecting the oceans and social responsibility. Autoneum Blue is a continuation of the LABEL blue by Borgers®, which was originally launched by Borgers Automotive. Following the acquisition of the German automotive supplier in April 2023, Autoneum has now fully integrated the label into its sustainable product portfolio.

Marine pollution has reached alarming levels in recent decades, with plastic contamination posing one of the most harmful threats to the health of the world’s largest ecosystem. In light of ever-stricter legal requirements for the environmental performance of vehicles, especially regarding the recycled content of components and their end-of-life recyclability, the reduction and recycling of plastics is also one of the key challenges for the automotive industry. Autoneum Pure, the Company’s sustainability label for technologies with an excellent sustainability performance throughout the product life cycle, is already successfully helping customers to tackle these challenges. With Autoneum Blue, Autoneum is now expanding its sustainable product portfolio with a label for components that combine the use of recycled material with protecting the oceans and social responsibility.

In order to qualify for the Autoneum Blue label, components must be based on materials that consist of at least 30% recycled PET that was collected from coastal areas within a 50-kilometer range of the water. These credentials mean the products make an important contribution to preventing plastic pollution in the oceans. In addition, the process of collecting the PET bottles must be socially respon-sible and comply with human rights, and traceable procurement of the bottle flakes must be guaran-teed. Autoneum Blue thus complements the Company’s strategic target to continuously reduce water consumption in all areas of its operations with an additional focus on preventing plastic pollution of the oceans.

Autoneum currently offers selected wheelhouse outer liners, needlepunch carpets and trunk side trim under the Blue label. In principle, however, the label could be extended to any product based on Autoneum technologies that feature recycled polyester fibers. As an addition to Autoneum’s existing fully recyclable monomaterial polyester constructions, which are characterized by waste-free production and have a significantly lower carbon footprint compared to products made from virgin fibers, Autoneum Blue presents another example of the Company’s ongoing efforts and continuous strides towards a sustainable circular economy.

Faster and more cost-effective carbon fibre production - the technology of the start-up CarboScreen comes a good deal closer to this dream. The founders Dr. Musa Akdere, Felix Pohlkemper and Tim Röding from the Institut für Textiltechnik (ITA) of RWTH Aachen University are using sensor technology to monitor carbon fibre production, thereby doubling the production speed from the current 15 to 30 m/min in the medium term and increasing turnover by up to €37.5 million per year and system. This ground-breaking development also impressed the jury at the ITMF at their Annual Conference in Keqiao, China, and was honoured with the ITMF StartUp Award 2023 on 6 November 2023.

Dr. Musa Akdere accepted the award on behalf of the CarboScreen founding team.

Carbon fibres can only develop their full potential if they are not damaged during production and further processing. Two types of fibre damage occur more frequently during fibre production: Superficial or mechanical damage to the fibres or damage to the chemical structure.

Both types of damage cannot be optimally detected by current means or only become apparent after production, to name just two examples. This leads to higher production costs. In an emergency, faulty production can even lead to plant fires. For this reason, and to ensure good production quality, the system is run at 15 m/min below its production capacity for safety reasons. However, 30 m/min or more would be possible. With the sensor-based online monitoring of CarboScreen, the production capacity can be doubled to 30 /min. This would lead to higher production, resulting in lower manufacturing costs and wider use of carbon fibres in mass markets such as automotive, aerospace and wind energy.

Felix Pohlkemper and Tim Röding from Institut für Textiltechnik (ITA) of RWTH Aachen University are developing a technology with their start-up CarboScreen GmbH that makes complex carbon fibre production controllable through sensor monitoring. With the help of CarboScreen technology, it should be possible to double the production speed from the current 15 m/min to 30 m/min in the medium term. The doubling of production speed alone could result in an increase in turnover of up to €37.5 million per year and production plant. Felix Pohlkemper and Tim Röding were awarded third place in the AVK Innovation Award 2023 in the Processes and Procedures category for this ground-breaking development. The award ceremony took place during the JEC Roof Forum in Salzburg, Austria.

The production of carbon fibres is highly complex. In the current state of the art, however, the manufacturing process is only monitored manually by semi-skilled workers. However, even minimal fibre damage during production leads to a reduction in the quality of the carbon fibre. In extreme cases, it can also lead to plant fires. To ensure production quality, the production speed is currently limited to a maximum of 15 m/min. In fact, the production speed of the systems could be higher. The sensor-based online monitoring of Carbo-Screen makes it possible to increase the production speed to 30 m/min in the medium term. As a result of the increased production volume per system, the specific production costs of the carbon fibre are reduced, which can result in lower prices.

A reduced sales price would make it possible to use carbon fibres and their composite materials even more widely in traditional markets such as aerospace technology and wind energy, as well as for mass production in the automotive industry.

The CarboScreen online monitoring system is currently being developed for industrial use. It is to be validated at an industrial plant in 2024. CarboScreen GmbH was founded as part of EXIST funding and offers AI-supported sensor systems for carbon fibre production. The sensor technology continuously monitors the fibre throughout the entire production process. Deviations are detected automatically.

The winners of the AVK Innovation Award are honoured annually by the AVK Industrievereinigung Verstärkte Kunststoffe. Companies, institutes and their partners are honoured in three categories: products and applications, processes and procedures, and research and science.

Trumpler has teamed up with Archroma to offer a leather production process that can be used to produce high-performance leather in a more eco-friendly and cost-efficient way.

The new process DyTan®combines offers an alternative to existing metal-free and chrome-tanned leather. It enables the reliable production of leather with great shavability, color depth and migration and abrasion resistance. Free from metal salts and reactive aldehydes, DyTan® is suitable for a wide range of leather applications, from garment and footwear to automotive and furniture upholstery, for today’s eco-conscious leather producers and consumers.

At the core of the DyTan® process is Archroma’s patented AVICUERO® System, which is based on novel molecules that enable more sustainable leather tanning and dyeing, developed by Archroma in cooperation with leather technology consultant Dr Leather. It enables collagen fibers in the leather to be covalently cross-linked through a simplified process at low temperatures. As a result, the system shows strong potential to save energy and water, while also reducing process time and CO₂ emissions by up to 23%.*

The DyTan® process combines the AVICUERO® System with Trumpler’s bio-based fatliquors and retanning agents based on functional biopolymers produced from hydrolyzed shavings – resource-saving technology that Trumpler has been refining for 15 years.

As a global partner of Archroma, the Trumpler Group is responsible for the distribution of the AVICUERO® System worldwide. Delivering technical support and first-class customer care, Trumpler will help leather manufacturers and brands to implement sustainable tanning and draw on its comprehensive product portfolio and process knowledge of tanning, retanning and fatliquoring processes.
 

* Estimations carried out with the Archroma ONE WAY Impact Calculator show energy savings of up to 25% and reduced process time leading to a reduction in CO₂ emissions of up to 23%, compared to traditional chrome tanning. They also show significant water savings compared to other metal-free tanning systems¹. With the ONE WAY Impact Calculator, customers will be offered personalized calculations for their specific processes.

¹ Trials made at Trumpler GmbH application lab.

Solvay announced the future Board of Directors of SYENSQO, effective upon completion of the planned separation of Solvay into two companies – SOLVAY and SYENSQO – which is on track to be completed in December 2023.

SYENSQO’s Board will be composed of 10 members, including 6 independent members, 3 members representing the reference shareholder, Solvac, and the company CEO. They have deep expertise in specialty industries, international business operations, risk management, corporate governance, finance and clean technology.

The following individuals will serve on the SYENSQO Board of Directors:
Rosemary Thorne will serve as independent Director and Chair of the SYENSQO Board, as well as Chair of the Board’s Finance Committee. She is currently an Independent Director on the Solvay Board of Directors, appointed in 2014, and Chair of the Board’s Audit Committee. She is also an Independent Director on the Board of Merrill Lynch International (UK), a wholly-owned subsidiary of Bank of America, serving as Chair of the Audit Committee. Ms. Thorne has decades of financial leadership experience across a wide range of industries. She previously served as Chief Financial Officer at J. Sainsbury, the UK’s largest supermarket chain at the time; Bradford & Bingley; and Ladbrokes. Ms. Thorne previously sat as an Independent Director on the Boards of Royal Mail Group, Cadbury Schweppes, Santander UK, First Global Trust Bank and Smurfit Kappa Group.

Dr. Ilham Kadri will serve as Chief Executive Officer and member of the Board of Directors of SYENSQO. She is currently CEO and President of the Executive Committee at Solvay. Ms. Kadri has successfully led the turnaround of Solvay, delivering double-digit EBITDA growth and 18 consecutive quarters of positive free cash flow, deleveraging the balance sheet and promoting superior people engagement. She is an independent Board member at A.O. Smith and L’Oréal. She is active in non-profit organizations, as Chair of the World Business Council for Sustainable Development (WBCSD), member of the steering committee of the European Round Table of Industrialists (ERT) as well as a permanent member of the World Economic Forum’s International Business Council (WEF). Ms. Kadri has extensive leadership experience across a variety of industries in four continents and with leading industrial multinationals, including Shell, UCB, Huntsman, Dow, Sealed Air. Prior to Solvay, she was CEO and President of Diversey in the USA, led the company’s return to profitability and resulting spin off and divestiture to Bain Capital. She founded two non-Profit foundations: the Solvay Solidarity Fund in Belgium in 2020 which supported more than 7000 families affected by Covid-19 and natural disasters; and founded the ISSA Hygieia Network in 2015 in the USA, to help women in the cleaning industry. She received two Doctor Honoris Clausa from EWHA University in Korea and Université de Namur in Belgium.

Julian Waldron will serve as independent Director and Chair of the Audit Committee. He currently serves as Deputy Executive Chairman of privately-held Albea Group, a global beauty and personal care packaging company which operates 35 facilities in Europe, Asia and the Americas. Mr. Waldron has held senior leadership roles at several leading listed companies in the industrial, technology and services sectors and brings a wealth of expertise in finance and business operations. Prior to joining Albea in 2022, he was Chief Financial Officer of Suez for three years after serving as Chief Financial Officer and subsequently Chief Operating Officer of Technip. He started his career at UBS Warburg where he spent 14 years. Mr. Waldron also served as an independent Board member and Chairman of finance, risk and investments at Carbon Clean, a privately-owned carbon capture company dedicated to achieving net zero.

Heike Van de Kerkhof will serve as independent Director and Chair of the Nomination Committee. She currently sits on the Board of OCI N.V.. Ms. Van de Kerkhof brings more than 30 years of experience in the chemicals, oil & gas and materials industries, having served in numerous leadership roles around the globe. From 2020 to 2023, she was Chief Executive Officer of Archroma Management, a global specialty chemicals company. During her tenure, she successfully completed the transformational acquisition of Huntsman’s Textile Effects business. Prior to her role at Archroma, Ms. Van de Kerkhof served as Vice President of Lubricants, Western Hemisphere at BP, and held positions at Castrol, The Chemours Company, and Neste Corporation. She also held many leading roles within DuPont over 18 years.

Matti Lievonen will serve as independent Director and Chair of the Compensation Committee. He is currently an independent director on the Solvay Board, appointed in 2017. Mr. Lievonen is a proven executive in the energy, forestry, power and automation industries with an extensive track record of leading businesses through climate transition. For over ten years until 2018, he served as Chairman and Chief Executive Officer of Neste Corporation, a global leader in next-generation renewable fuels and chemicals. During his time at Neste, Mr. Lievonen successfully promoted the development of clean fuels as well as Finland’s bioeconomy strategy in advancing renewable transportation fuels. He has also been involved with organizations such as Fortum Board, SSAB, Nynäs AB, Ilmarinen, and the HE Finnish Fair Foundation. Until 2021, Mr. Lievonen was also Chairman of the Board of Directors at Fortum. He has been recognized for his admirable leadership and expertise, and in 2016 was awarded an Honorary Doctorate of Technology by the Aalto University Schools of Technology.

Dr. Françoise de Viron will serve as non-independent Director, Chair of the ESG Committee and Vice-Chair of the Board. She is currently a director of the Solvay Board, appointed in 2013. Ms. de Viron is a regarded academic leader and has extensive experience in innovation, R&D and qualitative research. She is a Professor Emeritus at the Faculty of Psychology and Education Sciences and Louvain School of Management at UCLouvain in Belgium where she has been an Academic Member of various groups at UCLouvain. Ms. de Viron previously served as the president of AISBL EUCEN – the European Universities Continuing Education Network. Prior to her university position, from 1985 to 2000, she was in charge of developing Artificial Intelligence applications at Tractebel S.A. (now Tractebel-Engie).

Roeland Baan will serve as independent Director. He currently serves as President and Chief Executive Officer of Topsoe, a privately-held leading provider of clean energy and petrochemical technologies. He is also Chairman of the Supervisory Board of SBM Offshore NV. Roeland Baan has extensive experience in supply chain management, M&A, business development and operations management. Prior to joining Topsoe in 2020, he was President and CEO of Outokumpu and has held several executive roles at global organizations such as Aleris International, ArcelorMittal and SHV NV. He spent over 16 years in various roles across the globe at Shell, living in South America, in Africa and in the United Kingdom.

Edouard Janssen will serve as non-independent Director. He is currently a Director on the Solvay Board, appointed in 2021. Earlier this year, he was appointed Chief Financial Officer of D’Ieteren Group, a European leader in automotive distribution services. Mr. Janssen is also a Board member of privately-held Financière de Tubize and Union Financière Boël, as well as Co-Founder and Chair of Trusted Family. Mr. Janssen is active in academics, as Vice-Chair of the International Advisory Board of the Solvay Brussels School of Economics and Management and on the advisory board of the INSEAD HGIBS. He brings expertise in finance, strategy, entrepreneurship, business management, planning and marketing. He has served as Solvay’s Vice President in strategy and M&A between 2019 and 2021, and prior to that, he was the US-based General Manager for North- and Latin America at Solvay’s Aroma Performance Global Business Unit.
 
Dr. Mary Meaney will serve as non-independent Director. She is currently a member of the Board of Directors and of the Audit Committee of Groupe Bruxelles Lambert SA. She also sits on the Board of Directors and the Remuneration Committee of Beamery, the privately-held talent management company. She is a member of the Board of Directors and of the Finance Committee of Imperial College, London.Dr. Meaney will bring expertise in Strategy, M&A, and change management, which she acquired over a 24-year career at McKinsey. She was a Senior Partner, served on the McKinsey Shareholders Council and led McKinsey’s global Organization practice.

Nadine Leslie will serve as independent Director and is based in the United States of America. She is currently a member of the Board of Directors of Provident Financial Services , as well as a Non-Executive Director of Seven Seas Water Corporation, a water and wastewater treatment multinational company. She also sits on the Board of Trustees of Hackensack Meridian Health Network and is active as strategic consultant for civil engineering firm T&M Associates. Over a 22-year career at Suez, Ms. Leslie held several leadership positions, the last one being Chief Executive Officer of Suez North America, until 2022. Previously she served as Executive Vice President Health & Safety.

Archroma and Shima Seiki have expanded their partnership to bring the industry’s largest library of colors for cotton and polyester to the SDS®-ONE APEX design, planning and virtual sampling system and APEXFiz® (hereafter SDS®-ONE APEX series) subscription software.

Now offering a total of 5,760 color references, SDS-ONE APEX series has added all 1,440 colors for polyester from The Color Atlas by Archroma® to its color library of 4,320 Color Atlas colors for cotton poplin. The new polyester collection ranges from neutral earth tones to vibrant jewel tones and on-trend fluorescent colors, with shades suitable for sportswear, fashion, home furnishings, automotive textiles and more.

The extended color library in SDS®-ONE APEX series will help designers and manufacturers to visualize and evaluate their design choices on realistic fabric simulations and then put them into production with dyes and finishes that meet their desired sustainability profile. The Shima Seiki system also offers a smooth transition to machine programming for quick and accurate production, reduced waste and accelerated time to market.

Each of the 5,760 Color Atlas color references in the SDS®-ONE APEX series design software is available as a physical color standard that includes precise dyeing recipes and compliance data, as well as access to expert technical support from Archroma around the world.

“Polyester remains the most popular choice across many textile segments where high performance is a must. Users of Shima Seiki’s advanced SDS®-ONE APEX series platform will now be able to select from the industry’s largest library of colors for both cotton and polyester and, more importantly, trust that their choice can be reliably executed,” Chris Hipps, Head of Strategic Business Development, Archroma Color Management, said.

“Our colors are formulated with dyes that comply with international eco-standards and work with Archroma’s groundbreaking coloration systems, like FAST SPORT,” he continued.

Lectra, a leader in technology solutions for the fashion, automotive and furniture industries, will be listed in the CAC Mid 60 and SBF 120 indices of Euronext as of market close on September 15, 2023. This listing will enhance the visibility of the group with potential shareholders and customers in France and internationally.

Founded 50 years ago, the Lectra Group offers software, connected cutting equipment, data analysis solutions and associated services to players in the fashion, automotive and furniture industries to accelerate their digital transformation and transition to Industry 4.0. In 2017, the company initiated its Lectra 4.0 strategy, with the ambition of becoming an indispensable player in Industry 4.0 worldwide by 2030.

For Daniel Harari, Chairman and Chief Executive Officer of Lectra: “Lectra's entry into the CAC Mid 60 and SBF 120 indices is an outstanding recognition of the successful actions we have taken over the past few years to ensure the profitable growth of our company and the success of our customers. We have changed dimension, notably with the acquisition of our historical competitor, Gerber Technology in June 2021. We have expanded our customer base, launched new cloud-based offerings which have enabled us to significantly increase the volume of SaaS software in our revenues, and offered new Customer Success Management services to support our customers. We have also made Corporate Social Responsibility (CSR) one of the pillars of our strategy.”

Freudenberg Performance Materials (Freudenberg) is extending its recently-introduced ECO range of sustainable nonwoven carpet backings: Lutradur ECO-R and Colback ECO-R backings contain high percentages of recycled raw materials. With its ECO portfolio Freudenberg supports carpet manufacturers in their transition towards an increasingly sustainable product offering.

The company launched its ECO range for sustainable primary backings earlier this year with the introduction of the ECO-RE resource-efficient backings that use less raw materials and support end product recyclability. To achieve this, Freudenberg R&D teams further developed the company’s proprietary yarn production technology allowing for extremely thin filaments.

ECO-R products
Freudenberg’s spunbond nonwoven primary and secondary carpet backings contribute to manufacturers’ easy and efficient production processes as well as to high-performance end products. The company is now extending its ECO range in Europe with Colback ECO-R and Lutradur ECO-R backings that contain a recycled content of between 51 and 90%. Replacing virgin raw materials with recycled polyester saves on natural resources and improves the carbon footprint of end products. The ECO-R backings are specifically suitable for carpet tiles, broadloom, dust control mats and automotive option mats.

•    First production supercar created with Hypetex coloured carbon fibre
•    Paint-replacement technology reduces weight to enhance performance

British car manufacturer Briggs Automotive Company (BAC) has created a unique Hypetex coloured carbon fibre version of its Mono R, reducing the weight by removing the need for paint.  

The original BAC Mono R was created to be lighter and more powerful than the standard model, with 343bhp and 555kg total weight, equating to a power-to-weight ratio of 618bhp-per-tonne. By removing the need for paint coatings in this version, the net weight of the exterior is reduced compared to a painted shell, resulting in a further improved overall performance.

The car’s body was created using Hypetex’s titanium carbon fibre twill, and finished with a crystalized lacquer, offering a unique aesthetic finish. The ultra-lightweight supercar can accelerate from zero to 60mph in less than 2.5 seconds.  

Hypetex’s paint-replacement technology retains the visible weave, allowing for a bold design and a choice of colours without technical compromises, perfectly aligning with BAC’s initiatives to maximise performance whilst creating bespoke supercars. Paint generally adds 138 grams per metre squared, whereas Hypetex adds just 17 grams for the same area, offering an 8x weight saving.
This bespoke version of BAC’s single-seater Mono R was subject to BAC’s renowned BAC Bespoke programme, which ensures that no two Monos are the same. The client, a US-based collector, worked with BAC’s design team to design the car to their personal taste.   

Born out of Formula 1 technology, Hypetex offers manufacturers sustainable aesthetic materials with technical and efficiency benefits. This collaboration is an all-British success story, with the Hypetex carbon fibre body built by Formaplex, a leading UK-based manufacturing company who manufacture lightweight engineered solutions for top tier customers in Automotive, Aerospace and Defence markets. BAC’s supply chain is 95% UK-based.  

Hypetex continues to expand its growing portfolio of the use of coloured carbon fibre to add personalisation to the automotive field, with its material recently featured on the 2024 Ford Mustang Dark Horse.